Roofing tile system and method

Title: Roofing tile system and method.Abstract: Provided is roofing tile system that includes a roofing tile having a substantially wedge shaped tile body. The tile body including a bottom surface to be disposed adjacent a roofing deck during use, a top surface angled relative to the bottom surface, such that a first end of the wedge shaped body has a first height and a second end of the tile body has a second height that is greater than the first height, and a recess extending into the bottom surface at the second end. The recess is shaped substantially complementary to the first end of the tile body. ...

BACKGROUND

The present invention generally relates to roofing systems and methods and more particularly to roofing tile systems and methods.

2. Description of Related Art

Roofs are typically installed on top of a structure (e.g., a home, commercial building, pavilion, etc.) to provide a barrier to environmental conditions. Roofs may shield an interior of a structure from environmental sun, wind, rain, hail and so forth. A roof often includes a plurality of shingles or tiles overlapped in a series of rows to provide a protective barrier. Roofing shingles and tiles are often formed of a variety of materials, including, for example, wood, asphalt, stone, clay, ceramics, and the like.

Roofing shingles and tiles are often overlapped and/or interlocked with one another to provide a roofing surface. For example, roofing tiles may be interlocked with adjacent roofing tiles to provide a system of interlocked tiles to provide a tiled roof surface. Unfortunately, roofing shingles and tiles may suffer from a number of issues. For example, interlocking tiles may include a variety of complex features that make them both difficult to manufacture and difficult to install. Moreover, once installed roofing shingles and tiles may not adequately protect the structure. For example, gaps between shingles and tiles may leave them susceptible to lift in windy conditions and may allow water to penetrate the roof and the underlying structure.

Accordingly it is desirable to provide a roofing member that is relatively simple to install and/or manufacture and/or provides an adequate barrier to the elements.

SUMMARY

Various embodiments of roofing systems and related apparatus, and methods of employing the same are described. In one embodiment, a method includes a roofing tile system that includes a roofing tile having a substantially wedge shaped tile body. The tile body includes a bottom surface to be disposed adjacent a roofing deck during use, a top surface angled relative to the bottom surface, such that a first end of the wedge shaped body has a first height and a second end of the tile body has a second height that is greater than the first height, and a recess extending into the bottom surface at the second end. The recess is shaped substantially complementary to the first end of the tile body.

In another embodiment, provided is a roofing system including a plurality of roofing tiles. The roofing tiles having a substantially wedge shaped tile body including a bottom surface to be disposed adjacent a roofing deck during use, a top surface angled relative to the bottom surface, such that a first end of the wedge shaped body has a first height and a second end of the tile body has a second height that is greater than the first height, and a recess extending into the bottom surface at the second end. The recess is shaped substantially complementary to the first end of the tile body. The first end of the roofing tiles is to be disposed within a recess of another one of the plurality of roofing tiles.

In another embodiment, provided is a roofing method that includes disposing, on a roofing surface, a first roofing tile having a substantially wedge shaped tile body that includes a bottom surface to be disposed adjacent a roofing deck during use, a top surface angled relative to the bottom surface, such that a first end of the wedge shaped body comprises a first height and a second end of the tile body has a second height that is greater than the first height, and a recess extending into the bottom surface at the second end. The recess is shaped substantially complementary to the first end of the tile body of the first roofing tile. The method further includes disposing, on the roofing surface, a second roofing tile having a substantially wedge shaped tile body that includes a bottom surface to be disposed adjacent a roofing deck during use, a top surface angled relative to the bottom surface, such that a first end of the wedge shaped body has a first height and a second end of the tile body has a second height that is greater than the first height, and a recess extending into the bottom surface at the second end. The recess is shaped substantially complementary to the first end of the tile body of the second roofing tile. The recess of the second tile is disposed over the first end of the first tile such that the first end of the first roofing tile is disposed within the recess of the second roofing tile and at least a portion of the first end of the first roofing tile is overlapped at least partially by at least a portion of the second end of the second tile.

BRIEF DESCRIPTION OF THE DRAWINGS

Advantages of the present invention will become apparent to those skilled in the art with the benefit of the following detailed description and upon reference to the accompanying drawings in which:

FIG. 1 is a diagram that illustrates a tile roofing system in accordance with embodiments of the present technique;

FIGS. 2A and 2B are diagrams that illustrate a cross-sectioned perspective view and a cross-sectioned side view, respectively, of overlapping tiles of the roofing system in accordance with embodiments of the present technique;

FIGS. 3A-3G are diagrams that illustrate a topside perspective view, a bottom-side perspective view, a topside view, a side view, a bottom-side view, a left/upper-end view and a right/lower-end view, respectively, of a stacking tile of the roofing system in accordance with embodiments of the present technique;

FIGS. 4A-4G are diagrams that illustrate a topside perspective view, a bottom-side perspective view, a topside view, a side view, a bottom-side view, a left/upper-end view and a right/lower-end view, respectively, of a terminating tile of the roofing system in accordance with embodiments of the present technique;

FIG. 5 is a flow chart illustrating a method of installing the roofing system in accordance with embodiments of the present technique.

While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof are shown by way of example in the drawings and will herein be described in detail. The drawings may not be to scale. It should be understood, however, that the drawings and detailed description thereto are not intended to limit the invention to the particular form disclosed, but to the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present invention as defined by the appended claims.

DETAILED DESCRIPTION

As discussed in more detail below, certain embodiments of the present technique include a roofing tile system and method. In some embodiments, roofing tiles include a substantially wedge shape body having bottom and top surface angles relative to one another. In some embodiments, the wedge-shaped tile includes a substantially flat bottom surface and a flat top surface angled (e.g., about 0.5 degrees (°) to about 2 degrees (°) relative to the lower surface. In some embodiments, the angled upper surface may provide for a relatively thick lower-end and a relatively thin upper-end of each of the tiles. In certain embodiments, the substantially flat bottom surface may lie substantially flat against the supporting roofing surface/deck when installed, such that the bottom surface is substantially parallel to the supporting roofing surface/deck. In certain embodiments, an upper-end of each of the tiles may be overlapped by a lower-end of a tile stacked immediately above the tile on the supporting roofing surface/deck (e.g., lower end of tiles in a higher row overlapping upper ends of tiles in a lower row). In some embodiments, the bottom surface of the lower-end of each of the tiles includes a laterally extending recess/pocket that overlaps an upper end of tile(s) located immediately below the tile (e.g., tiles disposed in a lower row). In certain embodiments, the recess/pocket may be shaped substantially complementary to the wedge shaped upper end of the tiles such that a close fit is provided between the lower end of the tiles overlapping the upper ends of other tiles. In some embodiments, overlap between adjacent tiles is less than about 25% of their length. In certain embodiments, recesses, standoffs, or other texture may be provided on either of the bottom and top surfaces. In some embodiments, one or more fastener holes (e.g., for a nail or screw) is provided proximate the upper-end of the tiles. In certain embodiments, a single fastener hole is provided proximate the upper-end of the tiles. In some embodiments, a terminating/end tile to be disposed at the lower edge of the roof includes a substantially wedge shape and a lip extending downward from the bottom surface at or near a lower-end of the tile. In certain embodiments, the tiles may be formed from a lightweight composite, such as a lightweight concrete.

FIG. 1 is a diagram that illustrates a tile roofing system 100 in accordance with embodiments of the present technique. Roofing system 100 includes a plurality of roofing tiles 102 disposed on a roofing support surface/deck 104. Tiles 102 may be disposed in a series of overlapping rows 106a, 106b, and 106c (e.g., collectively referred to herein as rows 106) to form a tile roofing surface 107. Roofing surface 107 may include a lower portion/end 107a and an upper portion/end 107b. In some embodiments tiles 102 include a combination of stacking tiles 108 and end (e.g., terminating) tiles 110. As described herein, terminating tiles 110 may include tiles 102 to be disposed in a lower/first row of tiles (e.g., row 106a) located a lower edge/lip 112 of roofing support surface/deck 104. As described herein, stacking tiles 108 may include tiles 102 to be disposed in upper rows of tiles (e.g., rows 106a and 106b) disposed above one or more lower rows of tiles.

FIGS. 2A and 2B are diagrams that illustrate a cross-sectioned perspective view and a cross-sectioned side view, respectively, of overlapping tiles 102 of roofing system 100 in accordance with embodiments of the present technique. FIGS. 3A-3G are diagrams that illustrate a topside perspective view, a bottom/under-side perspective view, a topside view, a side view, a bottom/under-side view, a left/upper-end view and a right/lower-end view, respectively, of a stacking tile 108 of roofing system 100 in accordance with embodiments of the present technique. FIGS. 4A-4G are diagrams that illustrate a topside perspective view, a bottom/under-side perspective view, a topside view, a side view, a bottom/under-side view, a left/upper-end view and a right/lower-end view, respectively, of a terminating tile 110 of roofing system 100 in accordance with embodiments of the present technique.

Roofing support surface/deck (“roof deck”) 104 may include a structure on which tiles, shingles, or the like are disposed. In some embodiments, roof deck 104 may include a roofing material layer that is disposed between primary structural components (e.g., trusses and/or roof joints) and tiles 102. In some embodiments, roofing deck 104 may include a substantially flat deck surface 120 (see FIG. 2B). Roofing deck 104 may include plywood, oriented strand board (OSB), metal, composite, or the like. Roofing deck may include planar sheathing having a substantially flat outer/upper surface on which tiles 102 are to be disposed. Roofing deck 104 may be oriented flat or angled/slanted to define a roof pitch (see FIGS. 1A and 2A). A slanted/angled roof deck 104 may slope from an upper portion/end 104b to a lower portion/end 104a. The slant/angle may encourage water and other elements (e.g., debris) to flow/move in a downward direction from the upper portion toward the lower portion of roofing system 100. Accordingly, when tiles 102 are installed on roof deck 104, the resulting slant/angle/pith may encourage water and other elements (e.g., debris) to flow/move longitudinally across upper surfaces of tiles 102, in a downward direction from upper portion/end 107b to lower portion/end 107a of roofing surface 107.

Roofing surface 107 may include a plurality of rows 106 of tiles 102 to cover some, all, or substantially all of a roof deck 104. For example, in the illustrated embodiment row 106a of terminating tiles 110 is located at a lower end 107a of roofing surface 107, row 106b of staking tiles 108 is disposed immediately above row 106a, and a second row 106c of staking tiles 108 is disposed immediately above row 106a of stacking tiles 108. Although three rows 106 are depicted in the illustrated embodiments, roofing system 100 may include any number of rows extending between a lower portion/end 107a and an upper portion/end 107b. Rows 106 may extend from a lower end portion 104a of roof deck 104 to an upper end portion 104b of roof deck 104. In some embodiments, a lower end portion 110a of terminating tiles 110 may extend over a lower edge/lip 112 of roofing support surface/deck 104. In some embodiments, a lower end portion 108a of stacking tiles 108 may overlap upper end portions of tiles 102 located immediately there below. For example, each of stacking tiles 108 of row 106b may include a lower end portion 108a that overlaps an upper end portion 110b of terminating tiles 110, and each of stacking tiles 108 of row 106c may include a lower end portion 108a that overlaps an upper end portion 108b stacking tiles 108 of row 106b.

In some embodiments, tiles 102 of roofing surface 107 in adjacent rows may be laterally staggered/offset such that lateral (e.g., left and right) edges of tiles 102 do not align with (e.g., are offset from) the lateral edges of tiles 102 located in rows immediately above and/or immediately below. For example, as depicted in at least FIG. 1, tiles 108 of row 106b are laterally offset from terminating tiles 110 of row 106a and stacking tiles 108 by about 50% of their widths. In some embodiments, tiles may be staggered by different amounts (e.g., about 10%, 20%, 30%, 40% of their width). In some embodiments, tiles 102 may have a variety of different widths such that staggering/offset may occur as a result of the varying widths of adjacent tiles 102.

In some embodiments, a flashing or cap tile may be placed over upper ends of tiles 102 located at near the uppermost portion of roofing surface 107 to seal the upper end and/or facilitate the flow of water or other debris down the roofing surface 107. For example, where upper end portion 107b abuts a vertical wall, flashing may adhered to the wall and overlap upper end portions of stacking tiles 108 of row 106c. Where upper end portion 107b meet an upper end portion of an adjacent roofing surface 107 (e.g., to form a ridge), a cap tile (e.g., a substantially “V” shaped tile) may be placed atop the ridge to overlap upper end portions 107b of the roofing surfaces (e.g., overlap upper end portions of tiles located at the top rows of the roofing surfaces).

As depicted in at least FIGS. 3A-3G, stacking tiles 108 may include a generally wedge shaped body 200. Wedge shaped body 200 may include a bottom surface 202 and a top surface 204. Bottom surface 202 may include a substantially flat surface. Bottom surface 202 may define an underside of stacking tile 108 that is to be disposed on or near facing deck surface 120 of roofing deck 104 during use (see at least FIG. 2B). For example, stacking tile 108 may be disposed on deck surface 120 such that bottom surface 202 is in contact or near contact with deck surface 120. In some embodiments, bottom surface 202 may include a substantially flat surface. In some embodiments, bottom surface 202 may be substantially flush/parallel with deck surface 120 such that no gap or a minimal gap exists between bottom surface 202 and deck surface 120. Reducing a gap between bottom surface 202 and deck surface 120 may help to reduce pockets for air to pass through which may result uplift of tile 108 during windy conditions.

In some embodiments, bottom surface 202 may include one or more protrusions or recesses. Bottom surface 202 may include one or more standoffs (e.g., bumps, texture or other protrusions) that provide for a slight gap between bottom surface 202 and deck surface 120. Bottom surface 202 may include one or more recesses (e.g., cuts, grooves or other recesses) that provide for paths between bottom surface 202 and deck surface 120. Where water or other debris penetrates roofing surface 107, a slight gap and/or recess, may facilitate the flow of the water or other debris between deck surface 120 and bottom surface 202 such that the water or debris can be cleared from underneath tile 108. In some embodiments, the slight air gap may facilitate the passage of at least some air between deck surface 120 and bottom surface 202, e.g., to facilitate the drying of moisture underneath tile 108 and/or dispersal of heat.

Top surface 204 may define a top-side of stacking tile 108 that is exposed to the environment when staking tile 108 is disposed on roofing deck 104 during use (see at least FIG. 2B). For example, stacking tile 108 may be disposed on deck surface 120 such that top surface 204 is directly exposed to sun, rain, wind and other environmental conditions. In some embodiments, top surface 204 includes a substantially flat surface. In some embodiments, top surface 204 may include a texture (e.g., a texture that is impact resistant and/or reflective) or other surface features. Top surface 204 may extend from an upper end 206 to a lower end 208 of tile 108.

In some embodiments, top surface 204 is angled with respect to bottom surface 202. For example, in the illustrated embodiments, top surface 204 angles away from bottom surface 202 from upper end portion 108b to lower end portion 108a. In some embodiments, upper surface and lower surface are separated by an angle 210 of about 0.5° to about 3°. For example, angle 210 may be about 2°. An angle may selected to provide for a tile of a sufficient length with out a relatively large thickness, thereby providing for an increased coverage/surface area without substantially increasing the weight of tile 108 and, thus, without substantially increasing the weight of roofing surface 107.

In some embodiments, lower end portion 108a of stacking tile 108 includes a recess 216. Recess 216 may include a cut-out in body 202 that, during use, receives an upper end portion of a tile 102 located immediately below stacking tile 108. For example, when installed, recess 216 may receive (or otherwise be placed over) an upper end portion 108a of another stacking tile 108 and/or an upper end portion 110a of a terminating tile 110 (see at least FIGS. 1-2B).

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20130207|20130031864|roofing tile system and method|Provided is roofing tile system that includes a roofing tile having a substantially wedge shaped tile body. The tile body including a bottom surface to be disposed adjacent a roofing deck during use, a top surface angled relative to the bottom surface, such that a first end of the wedge |